Toshiba MJ 1011 User Manual
File No. 3110009
General Precautions for Installation/Servicing/Maintenance
The installation and service should be done by a qualified service technician.
1. When installing the Finisher MJ-1011 to the Plain Paper Copier, be sure to follow the
instructions described in the “Unpacking/Set-Up Procedure for the MJ-1011” booklet
which comes with each unit of the MJ-1011.
2. The MJ-1011 should be installed by an authorized/qualified person.
3. Before starting installation, servicing or maintenance work, be sure to unplug the copier
first.
4. When servicing or maintaining the MJ-1011, be careful about the rotating or operating
sections such as gears, pulleys, sprockets, cams, belts, etc.
5. When parts are disassembled, reassembly is basically the reverse of disassembly
unless otherwise noted in this manual or other related materials. Be careful not to
assemble small parts such as screws, washers, pins, E-rings, toothed washers to the
wrong places.
6. Basically, the machine should not be operated with any parts removed or disassembled.
7. Delicate parts for preventing safety hazard problems (such as breakers, thermofuses,
fuses, door switches, sensors, etc. if any) should be handled/installed/adjusted correctly.
8. Use suitable measuring instruments and tools.
9. During servicing or maintenance work, be sure to check the serial No. plate and other
cautionary labels (if any) to see if they are clean and firmly fixed. If not, take appropriate actions.
10. The PC board must be stored in an anti-electrostatic bag and handled carefully using
a wristband, because the ICs on it may be damaged due to static electricity. Before
using the wrist band, pull out the power cord plug of the copier and make sure that
there is no uninsulated charged objects in the vicinity.
11. For the recovery and disposal of used MJ-1011s, consumable parts and packing materials, it is recommended that the relevant local regulations/rules should be followed.
12. When the Finisher is to be carried, be sure to hold the locations shown in the figures.
13. Place the finisher as shown in the figure below making sure that the cord is not nipped.
Copyright © 2000
TOSHIBA TEC Corporation
INTRODUCTION
This Service Manual contains basic data and figures for the Finisher MJ-1011 needed
to service the machine in the field.
Chapter 1 General Description introduces the finisher's features, specifications, and
names of parts, and shows how to operate the finisher.
Chapter 2 Basic Operation discusses the principles of operation used for the finisher's
mechanical and electrical systems. It also explains the timing at which these
systems are operated.
Chapter 3 Mechanical System discusses how the finisher is constructed mechanically,
and shows how it may be disassembled/assembled and adjusted.
Chapter 4 Maintenance and Inspection provides tables of periodically replaced parts and
consumables and durables, together with a scheduled servicing chart.
Chapter 5 Troubleshooting provides adjustments, problem identification and electrical
parts arrangement.
Appendix containts general timing chart, tables of signals, circuit diagram and
solvent/oils.
For installation, see the Installation Procedure that comes with the finisher.
The descriptions in this Service Manual are subject to change without notice for
product improvement or other purposes, and major changes will be communicated in the
form of Service Information bulletins.
All service persons are expected to have a good understanding of the contents of this
Service Manual and all relevant Service Information bulletins and be able to identify and
isolate faults in the machine.
i
CONTENTS
CHAPTER 1 GENERAL DESCRIPTION
I. FEATURES ..................................1-1
II. SPECIFICATIONS .......................1-2
III. OPERATING THE MACHINE ...... 1-6
CHAPTER 2 BASIC OPERATION
I. BASIC CONSTRUCTION ............2-1
II. BASIC OPERATIONS..................2-8
III. FEEDING DRIVE SYSTEM .......2-11
IV. INTERMEDIARY PROCESSING
TRAY ASSEMBLY......................2-13
CHAPTER 3 MECHANICAL SYSTEM
IV. MAINTENANCE BY THE
USER ........................................1-11
V. STAPLING ................................. 2-44
VI. OPERATIONS OF THE STACK
TRAY .........................................2-47
VII. DETECTING JAMS ...................2-56
VIII.POWER SUPPLY ...................... 2-61
I. EXTERNALS AND
CONTROLS.................................3-1
II. FEEDING SYSTEM .....................3-6
III. PROCESSING TRAY ...................3-7
IV. RETURNING ROLLER .............. 3-15
V. STACK TRAY .............................3-22
VI. STACK TRAY LIFTER
UNIT ..........................................3-23
VII. STAPLER...................................3-31
VIII.PCBs ......................................... 3-32
iii
CHAPTER 4 MAINTENANCE AND INSPECTION
I. PERIODICALLY REPLACED
PARTS.........................................4-1
II. CONSUMABLES AND
DURABLES .................................4-1
CHAPTER 5 TROUBLESHOOTING
I. ADJUSTMENTS ..........................5-1
II. TROUBLESHOOTING ...............5-12
APPENDIX
III. SCHEDULED MAINTENANCE ...4-1
III. ARRANGEMENT OF ELECTRICAL
PARTS .......................................5-17
A. GENERAL TIMING CHART........ A-1
B. SIGNALS AND
ABBREVIATIONS ....................... A-3
C. GENERAL CIRCUIT
DIAGRAM ................................... A-7
iv
D. FINISHER CONTROLLER
CIRCUIT DIAGRAM ................... A-8
E. SOLVENTS AND OILS ............. A-18
CHAPTER 1
GENERAL DESCRIPTION
I. FEATURES ..................................1-1
II. SPECIFICATIONS .......................1-2
III. OPERATING THE MACHINE ...... 1-6
IV. MAINTENANCE BY THE
USER ........................................1-11
CHAPTER 1 GENERAL DESCRIPTION
I. FEATURES
1. Small in Size, Light in Weight
• The finisher is designed as a small, light delivery device.
2. Mono-Frame
• The finisher is cased in a mono-frame, which has enabled reduction of the number of covers.
3. Sorting and Stapling by Stack Offset
• The finisher puts together stacks of sheets on its intermediary processing tray for offset
sorting and stapling.
4. Stack Tray
• The finisher’s stack tray is capable of holding as many as 900 sheets (BIN-1: 200 sheets,
BIN-2: 700 sheets) of small-size paper or 450 sheets (BIN-1: 100 sheets, BIN-2: 350 sheets)
of large-size paper.
Further, it can hold as many as 80 sets (BIN-1: 30 sets, BIN-2: 50 sets) of stapled stacks (each
consisting of up to 30 sheets).
1-1
CHAPTER 1 GENERAL DESCRIPTION
II. SPECIFICATIONS
A. Specifications
Item
Stacking
Stacking mode
Stack paper size
Paper weight
Bins
Modes
Stack tray capacity
[height (sheets)]
Simple
stacking
Job offset
Staple
stacking
Stacking
width*4
Stacking size
Stapling size
Stack offset width*6
Offset width*5
Not stapled
Stapled
A/B
Inch
Description
Stack tray (tray lift mechanisms, with intermediary tray fixed in position)
Face-down stacking
A3, A4, A4-R, A5-R, B4, B5, B5-R
LD, LG, LT, LT-R, ST-R, FOLIO, COMPUTER
50 to 200 g/m2 (Plain paper), 64 to 80 g/m2 (Recycled paper)
Stack tray 2
Intermediary processing tray 1
Staple stacking
Non-staple stacking
Non-staple offset stacking
Bin
1 30mm (200 sheets) 20mm (140 sheets) 15mm (100 sheets)
2 99mm (700 sheets) 70mm (490 sheets) 49mm (350 sheets)
1 30mm (200 sheets) 20mm (140 sheets) 15mm (100 sheets)
2 99mm (700 sheets) 70mm (490 sheets) 49mm (350 sheets)
1 30 sets (170 sheets) 30 sets (110 sheets) 30 sets (80 sheets)
2 50 sets (600 sheets) 50 sets (400 sheets) 50 sets (300 sheets)
139.7 to 297 mm
210 to 297 mm
A3, A4, A4-R, B4, B5
LD, LG, LT, LT-R, ST-R, FOLIO, COMPUTER
A3, A4, A4-R, B4, B5
LD, LG, LT, LT-R, FOLIO, COMPUTER
210 to 297 mm
20 mm
Small-size*1 Middle-size*2 Large-size*3
Plain Paper/Recycled Paper
Equivalent
of
80 g/m
paper
2
1-2
CHAPTER 1 GENERAL DESCRIPTION
Item
Stapling method
Stapling position
Stack thickness
Staple source
Staple
Staple detection
Manual stapling
Paper detection
Control panel
Display
Dimensions (W×D×H)
Weight
Power supply
Maximum power
consumption
Punching by rotating cam
1-point rear, slant (Figure 1-201)
Small-size 30 sheets max.
Medium-size 20 sheets max.
Large-size 15 sheets max.
Special cartridge (3,000 staples)
Special staple (STAPLE-1600)
Yes
No
Yes
No (operated from copier)
None (display on copier)
431 × 541 × 413 mm
17 kg
24V, 5V (from copier)
40W or less
Description
*1 Small-size, i.e., A4, A4-R, A5-R, B5, B5-R, postcard, LT, LT-R and ST-R.
*2 Medium-size, i.e., B4 and LG.
*3 Large-size, i.e., A3, FOLIO, COMPUTER and LD.
*4 The width of paper that may be put into order in the front/rear direction.
*5 The distance a stack is displaced during sorting.
*6 The width of paper that may be put into order during sorting.
45˚
5±4mm
5±4mm
Figure 1-201 Stapling Positions
1-3
CHAPTER 1 GENERAL DESCRIPTION
■ Cross Section
[10]
[14]
[1] [2] [3] [4] [5] [6]
[7]
[8]
[11A]
[9]
1-4
[11]
[12]
[13]
[1] Lower stack tray
[2] Jogging plate (front, rear)
[3] Paper feeding guide A
[4] Paper feeding guide B
[5] Delivery roller
[6] Paper path
[7] Returning roller
[8] Stopper plate
[9] Stapler unit
[10] Paper holding lever
[11] Stack delivery belt
[11A] Stack delivery lever
[12] Intermediary processing tray
[13] Frame
[14] Upper stack tray
Figure 1-202
■ Top View
CHAPTER 1 GENERAL DESCRIPTION
[1] [2]
[3]
[4] [5] [6]
[1] Stack delivery belt
[2] Rear jogging plate
[3] Grip
[4] Stack extension tray
[5] Stack tray
[6] Front jogging plate
Figure 1-203
1-5
CHAPTER 1 GENERAL DESCRIPTION
III. OPERATING THE MACHINE
A. Removing Paper Jams
If the Jam indicator is turned on to indicate the presence of a jam in the finisher, perform the
following:
1) Grasping the grip, disconnect the finisher from the copier.
Figure 1-301
2) Remove the paper visible from the outside.
Figure 1-302
Caution:
Do not remove the paper from the intermediary processing tray before removing the jam.
3) Connect the finisher to the copier.
1-6
Figure 1-303
CHAPTER 1 GENERAL DESCRIPTION
B. Supplying the Stapler Unit with Staples
If the Add Staples indicator turns on, perform the following:
1) Grasping the grip, disconnect the finisher from the copier.
Figure 1-304
2) Pick up the staple cartridge by its left and right side (light blue) and pull it off.
Figure 1-305
3) Pick up the empty staple case by its left and right side and pull it off.
Figure 1-306
1-7
CHAPTER 1 GENERAL DESCRIPTION
4) Set the new staple case.
Figure 1-307
Reference:
No more than one staple case may be set. Be sure to use a staple cartridge specially designed for
the machine.
5) Remove the seal used to hold the staples together by pulling it straight up.
Figure 1-308
6) Fit the staple cartridge into the stapler unit.
Figure 1-309
7) Connect the finisher to the copier.
1-8
Figure 1-310
CHAPTER 1 GENERAL DESCRIPTION
C. Removing a Staple Jam from the Stapler Unit
If the Staple Jam indicator turns on to indicate a staple jam in the stapler unit, perform the
following:
1) Remove the paper waiting to be stapled from the processing tray.
Figure 1-311
2) Grasping the grip, disconnect the finisher from the copier.
Figure 1-312
3) Pick up the staple cartridge by its left and right side (light blue) and pull it off.
Figure 1-313
1-9
CHAPTER 1 GENERAL DESCRIPTION
4) Shift down the staple cartridge.
Figure 1-314
5) Remove all staples that slid out of the staple case.
Figure 1-315
6) Shift the tab of the staple cartridge back to its initial position, and fit the staple cartridge into the
stapler unit.
Figure 1-316
7) Connect the finisher to the copier.
1-10
Figure 1-317
CHAPTER 1 GENERAL DESCRIPTION
IV. MAINTENANCE BY THE USER
A. Maintenance by the User
No.
Replacement of the staple cartridge
1
Item
Timing
When prompted on the copier’s display
Table 1-401
1-11
CHAPTER 2
BASIC OPERATION
I. BASIC CONSTRUCTION ............2-1
II. BASIC OPERATIONS ..................2-8
III. FEEDING DRIVE SYSTEM .......2-11
IV. INTERMEDIARY PROCESSING
TRAY ASSEMBLY......................2-13
V. STAPLING ................................. 2-44
VI. OPERATIONS OF THE STACK
TRAY .........................................2-47
VII. DETECTING JAMS ...................2-56
VIII.POWER SUPPLY ...................... 2-61
CHAPTER 2 BASIC OPERATION
I. BASIC CONSTRUCTION
A. Outline
The finisher consists of four blocks: intermediary processing tray assembly, stapler assembly,
and stack tray assembly. Figure 2-101 is a functional diagram of the finisher.
Delivery assembly
Intermediary
processing
tray assembly
Stack tray
assembly
Stapler
assembly
Figure 2-101
Finisher controller
PCB
2-1
CHAPTER 2 BASIC OPERATION
B. Outline of Electrical Circuitry
The finisher’s operation sequences are controlled by the finisher controller PCB, which is a 32-
bit CPU. The finisher controller PCB is also used to control communication (serial) with the copier.
The CPU on the finisher controller PCB is equipped with a built-in ROM used to store
operation sequence programs.
The finisher controller PCB drives solenoids, motors etc., in response to various commands
coming from the copier through serial communication lines. On the other hand, it communicates
the state of each sensor and switch to the copier in the serial mode of communication.
The ICs on the finisher controller PCB have the following functions:
■ IC1 (CPU): Controls sequence
■ IC2 (RAM): Stores various kinds of data temporarily
■ IC3 (ROM): Stores sequence program
■ IC4 (Communication IC): Communicates with the copier
Finisher controller
Solenoid
PCB
Motor
Sensor
Switch
IC1
CPU
IC2
RAM
IC3
ROM
IC4
Communication
IC
Copier
(CPU on DC
controller PCB)
2-2
Figure 2-102
CHAPTER 2 BASIC OPERATION
C. Inputs to and Outputs from the Finisher Controller PCB
• Inputs to the Finisher Controller PCB (1/3)
Delivery motor
clock sensor
Inlet paper sensor
Returning roller
home position sensor
Finisher joint sensor
Intermediary
processing tray
paper sensor
S1
S2
S3
S4
S5
J602
J605
J606
J609
J504
J601
J601
J601
J608
J501
Finisher controller PCB
J10
A1
A2
A3
B1
B2
B3
B4
B5
B6
A1
A2
A3
7
8
9
J10
J10
J11
J9
S1D
S2D
S3D
S4D
S5D
+5V
Pulses according to the rotation
speed of the delivery motor.
+5V
When paper is moving over
the sensor, '1'.
(The light-detecting plate is at S2.)
+5V
When the returning roller is
at the home position, '1'.
(The light-blocking plate is at S3.)
+5V
When the finisher is connected
to the copier, '0'.
(The light-blocking plate is not at S4.)
+5V
When paper is over the sensor, '1'.
(The light-blocking plate is at S5.)
A1
A2
A3
B1
B2
B3
B4
B5
B6
A1
A2
A3
7
8
9
Front jogging plate
home position sensor
Rear jogging plate
home position sensor
Stack delivery lever
home position sensor
Lower stack tray lift
motor clock sensor
S6
S7
S8
S9
J502
J503
J505
J603
Figure 2-103
J501
J501
J501
J601
10
11
12
A4
A5
A6
J9
1
2
3
4
5
6
10
11
12
A4
A5
A6
J9
J9
J10
S6D
S7D
S8D
S9D
+5V
When the front jogging plate is
at the home position, '1'.
(The light-blocking plate is at S6.)
+5V
When the rear jogging plate is
at the home position, '1'.
(The light-blocking plate is at S7.)
+5V
The stack delivery plate is
at the home position, '0'.
(The light-blocking plate is not at S8.)
+5V
Pulses according to the rotation speed
of the lower stack tray lift motor.
1
2
3
4
5
6
2-3
CHAPTER 2 BASIC OPERATION
• Inputs to the Finisher Controller PCB (2/3)
Stack tray paper
height sensor
Lower stack tray
paper sensor
Lower stack tray
lower limit sensor
Lower stack tray
upper limit sensor
Stapler safety
switch
S10
S11
S12
Sonser PCB
S13
S14
J1102 J1101 J902
J612
J612
11
11
12
12
13
13
N.O.
COM
J607
J611
Finisher controller PCB
J601
J10
+5V
B7
B7
B8
B8
S10D
B9
B9
J901
J15
1
2
3
J11
B3
B2
B1
J11
A7
A8
A9
J7
1
+5V
S10D
+5V
S12D
+5V
S13D
S14D
+24V
1
2
3
J608
B3
B2
B1
J608
A7
A8
A9
J801
212
When the top of paper is
detected,
'1'.
(The light-blocking is at S10.)
When paper is over the lower stack
tray paper sensor,
'1'.
(The light-blocking plate is at S11.)
When the lower stack tray is
at the lower limit,
'1'.
(The light-blocking plate is at S12.)
When the upper stack tray is
at the upper limit,
'1'.
(The light-blocking plate is not at
S13.)
When the switch is open,
'1'.
Staple edging
sensor
No-staple
detecting switch
Stapling home
position sensor
Stapler cartridge
detector switch
2-4
S15
S16
S17
S18
Stapler unit
J402
13
8
9
11
12
7
Figure 2-104
J401
13
13
8
9
11 11
12 12
7
8
9
7
J8
S15D
S16D
S17D
+5V
S18D
The tip of the staple is not at the
stapling position,
(The light-blocking plate is not at S15.)
When the stapler has no staples, '1
When the stapler is at the stapling
home position,
(The light-blocking plate is at S17.)
When the stapler cartridge is not set,
'1'.
'.
'0'.
'1'.
• Inputs to the Finisher Controller PCB (3/3)
10
J612
2
2
3
3
4
4
J612
5
5
6
6
7
7
J612
8
8
9
9
10
J704 J604
J702
Upper stack tray
lift motor
clock sensor
Upper stack tray
paper sensor
Stack tray
nearly full sensor
Upper stack tray
full sensor
Lower stack tray
full sensor
J705
S19
S20
J612
S21
J612
S22
J612
S23
Sensor PCB
J601
J701
J608
J608
J608
CHAPTER 2 BASIC OPERATION
Finisher controller PCB
J10
A7
A8
A9
J12
1
2
3
J11
B12
B11
B10
J11
B9
B8
B7
J11
B6
B5
B4
+5V
S19D
+5V
S20D
+5V
S21D
+5V
S22D
+5V
S23D
Pulses according to the rotation
speed of the upper stack tray
lift motor
When the paper is over the upper
stack tray paper sensor, '1'
(The light-blocking plate is at S20.)
When the upper/lower stack tray is
at the nearly full position, '1'
(The light-blocking plate is at S21.)
When the upper stack tray is
at the full position, '1'
(The light-blocking plate is at S22.)
When the lower stack tray is
at the full position, '1'
(The light-blocking plate is at S23.)
A7
A8
A9
1
2
3
B12
B11
B10
B9
B8
B7
B6
B5
B4
Stack tray collision
prevention sensor
Upper stack tray
upper limit sensor
Stack processing
safety switch
S24
S25
S26
COM
N.O.
J703
J610
J1202
Figure 2-105
J701
J608
A4
A5
A6
J1201
J12
4
5
6
A4
A5
A6
1
22
J11
J16
+5V
S24D
+5V
S25D
+24V
S26D
When the upper stack tray collides
with paper stacked on the lower
stack tray, '1'
(The light-blocking plate is at S24.)
When the upper stack tray is
at the upper limit, '1'
(The light-blocking plate is at S25.)
When the switch is open, '1'.
4
5
6
1
2-5
CHAPTER 2 BASIC OPERATION
• Outputs of the Finisher Controller PCB (1/2)
Delivery motor
Stack processing
motor
M1
J202J203
M2
Finisher controller PCB
J4
1
M1DA
2
M1DB
3
M1DA*
4
M1DB*
5
24V
6
J5
J201
1
1
M2DA
2
2
M2DB
3
3
M2DA*
4
4
M2DB*
5
5
6
6
By changing the sequence of drive
pulses (A, A*, B, B*) and the
frequency, the timing of the rotation
is controlled.
By changing the sequence of drive
pulses (A, A*, B, B*) and the
frequency, the timing of the rotation
is controlled.
(See p. 2-14)
24V
Front jogging motor
Rear jogging motor
Upper stack tray lift
motor
Stapler motor
M3
M4
M5
M6
Stapler unit
J306
J708
J402
J304
J305J307
J707
J302
J303
J301
J301
J401
10
11
12
J6
1
1
M3DA
2
2
M3DB
3
3
M3DA*
4
4
M3DB*
5
5
6
6
By changing the sequence of drive
pulses (A, A*, B, B*) and the
frequency, the timing of the rotation
is controlled.
24V
(See p.2-30.)
J6
7
7
M4DA
8
8
M4DB
9
9
M4DA*
10
M4DB*
11
12
J14J706
M5D1
121
2
M5D2
By changing the sequence of drive
pulses (A, A*, B, B*) and the
frequency, the timing of the rotation
is controlled.
(See p. 2-30)
24V
CW rotation at M5D1
CCW rotation at M5D1 '1', M5D2 '0
Stop at M5D1 '0', M5D2 '0
'0',
M5D2 '1
'.
'.
'.
J8
1
1
2
2
4
4
5
5
M6D1
M6D2
CW rotation at M6D1
CCW rotation at M6D1 '1', M6D2 '0
Stop at M6D1 '0', M6D2 '0
'0',
M6D2 '1
'.
'.
'.
2-6
Figure 2-106
• Outputs of the Finisher Controller PCB (2/2)
Lower stack tray
lifter motor
Paper holding lever
drive solenoid
M7
J1006 J1005
SL1
J1001J1003 J1002
J1004
CHAPTER 2 BASIC OPERATION
Finisher controller PCB
121
121
J3
2
J13
2
M7D1
M7D2
24V
SL1D
CW rotation at M7D1"0", M7D2"1"
CCW rotation at M7D1"1", M7D2"0"
Stop at M7D1"0", M7D2"0"
Solenoid ON at SL1D"0"
Figure 2-107
2-7
CHAPTER 2 BASIC OPERATION
II. BASIC OPERATIONS
The finisher is designed to operate as follows:
1. Paper arrives from the copier.
Figure 2-201
2. Paper reaches the intermediary processing tray.
Figure 2-202
2-8
CHAPTER 2 BASIC OPERATION
3. Paper is moved until it butts against the stopper plate by the work of the returning roller.
Figure 2-203
4. The paper is put into order by the work of the front/rear jogging plate.
Figure 2-204
2-9
CHAPTER 2 BASIC OPERATION
5. Operations 1 through 4 are repeated until a specific number of sheets have been stacked on the
intermediary processing tray.
6. The sheets are stapled (if stapling is selected).
Figure 2-205
7. The stack on the intermediary processing tray is moved to the stack tray.
Figure 2-206
2-10
CHAPTER 2 BASIC OPERATION
III. FEEDING DRIVE SYSTEM
A. Outline
Paper coming from the copier is sent to the intermediary processing tray, on which it is
arranged and offset/stapled for delivery to the stack tray.
The machine detects jams using the inlet sensor (S2).
Figure 2-301 shows the construction of the feeding drive system.
Notation
M1
M2
Feeding guide A
Returning roller
Delivery motor
Stack processing motor
S1
S2
S5
Delivery motor clock sensor
Inlet sensor
Intermediary processing tray paper sensor
Feeding guide B
Name
Table 2-301
S1
M1
S2
J10A-3
S1D
J4
Delivery roller
J10B-3
S2D
M2
Finisher controller PCB
J5
Stack delivery lever
S5
One-way clutch
J9-9
S5D
Figure 2-301
2-11
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